Microbiological and environmental control in poultry processing

ABSTRACT

Poultry carcasses are contacted with water treated with one or more specified dihalodialkylhydantoin biocides in a processing operation downstream from a scalding tank. The aqueous effluent from that downstream operation or from any location further downstream is recycled to the scalding tank. Surprisingly, the bromine residues from the dihalodialkylhydantoin biocides are much more thermally unstable than, for example, the commonly used microbiocide, sodium hypochlorite. Thus, the effluent from the scalding tank has its active bromine content significantly reduced before it is sent to a water purification facility wherein microbial action is used to reduce the BOD of the waste water before its release to the environment. Thus, injury to this desired microbial action is reduced. In addition, the recycle reduces water consumption in the overall poultry processing operation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.12/445,673, filed Apr. 15, 2009, now U.S. Pat. No. 9,277,755, which isthe National Stage of International Patent Application No.PCT/US2007/082063, filed on Oct. 22, 2007, which claims the benefit andpriority of U.S. Provisional Application No. 60/862,478, filed Oct. 23,2006. Each patent application identified above is incorporated here byreference in its entirety to provide continuity of disclosure.

BACKGROUND

Poultry processing is an area in which microbiological control is ofvital importance. By the very nature of the processing involved thereare numerous opportunities for the poultry to be exposed to variouspathogens in the form of mobile bacteria such as for example Escherichiacoli, Salmonella enteritidis, Salmonella typhimurim, Campylobacterjejuni, Campylobacter coli, Campylobacter lari, and in the form ofbiofilms such as for example Listeria monocytogenes, Pseudomonasfluorescens, Pseudomonas aeruginosa, Enterococcus faecium, andStaphylococcus aureus. Handling, processing and consumingbacteria-infested poultry is to be minimized, if not avoided.

In recent years, new effective microbiocides for use in the processingof poultry for food have been discovered and described. See for exampleU.S. Pat. Nos. 6,908,636; 6,919,364; 6,986,910 and U.S. PatentApplication Pub. No. 2006/0004072 A1.

In the processing of poultry for food, large quantities of water arenecessarily used. Recycle of water in the processing is a way ofreducing the amount of water used and the amount of wastewater produced.However, use of effective microbiocides in the processing operationsgives rise to problems associated with treating wastewater in order toreduce its biochemical oxygen demand (BOD) prior to release to theenvironment. These problems result from the fact that in order to reducethe BOD, microorganisms are utilized in the wastewater to destroyvarious impurities including organic matter. Thus, the wastewater itselfwhich contains biocidally-active residues from halogen-basedmicrobiocides, especially bromine-based microbiocides, tends to inhibitthe activity of such microorganisms because of the toxicity of theseresidues toward these microorganisms. Such microorganisms include forexample, floc-forming organisms, saprophytes, predators, and nuisanceorganisms. See in this connection Grady and Lim, Biological WastewaterTreatment, Marcel Dekker Inc., Copyright, 1980, Chapter 7.

Therefore, it would be highly desirable if a practical,economically-feasible way could be found for reducing water consumptionand discharge from operations in which poultry is processed for foodwhile at the same time, reducing the toxicity of the biocidally-activeresidues resulting from use of a halogen-based microbiocide in suchprocessing.

NON-LIMITING SUMMARY OF THE INVENTION

This invention is deemed to provide a practical, economically-feasibleway for reducing water consumption and discharge from operations inwhich poultry is processed for food while at the same time, reducing thetoxicity of the biocidally-active residues resulting from use of ahalogen-based microbiocide in such processing.

In accordance with one embodiment of this invention there is provided aprocess of processing poultry for food in a plurality of processingoperations, wherein the process comprises:

-   A) contacting poultry carcasses in one or more downstream processing    operations with an aqueous medium containing an effective microbial    inhibiting amount of active bromine resulting from the addition to    said medium of a microbiocide comprising (i) at least one    1,3-dihalo-5,5-dialkylhydantoin in which both of the halo atoms are    bromine atoms and one of the alkyl groups is a methyl group and the    other is a C₁₋₄ alkyl group or (ii) at least one    1,3-dihalo-5,5-dialkylhydantoin in which one of the halo atoms is a    bromine atom and the other is a chlorine atom, and both alkyl groups    are, independently, C₁₋₄ alkyl groups, or (iii) both of (i) and    (ii), said one or more downstream processing operations being    located downstream from a scalding operation;-   B) recycling to the scalding operation, effluent aqueous medium from    at least one downstream location which contains a microbial    inhibiting amount of active bromine resulting from the addition of    (i), (ii), or (iii); and-   C) having aqueous medium proceed, or causing aqueous medium to    proceed, from the scalding operation to a waste water purification    operation wherein microbial action is utilized to reduce the    biochemical oxygen demand of waste water from the process.    In preferred embodiments, the recycling in B) involves recycling to    the scalding operation, effluent aqueous medium from at least one of    the one or more downstream processing operations to which (i), (ii),    or (iii) was added in A). These downstream locations are preferred    because operations in a chill tank or in a post-chill dip or spray    operation, while feasible, involve use of cold water and thus    recycle of such cold water to the scalding operation requires the    input of additional heat energy to maintain the temperature of the    scalding operation in a suitable range, such as in the range of    about 50 to about 60 EC.

More preferably, effluent aqueous medium that is recycled in B) in theabove process is effluent aqueous medium or effluent aqueous media fromwhichever of the one or more downstream processing operations, (i),(ii), or (iii), was added in A).

Another preferred embodiment is a process as above wherein aqueousmedium to which (i), (ii), or (iii) is added in A) and which as effluentis recycled to the scalding operation in B) is effluent aqueous mediumfrom at least one operation selected from the group consisting of (a) aninside-outside bird washing operation, (b) a continuous onlineprocessing operation, (c) an offline reprocessing operation, and (d) aprechill spray operation. In this embodiment it is especially preferredthat the aforesaid effluent aqueous medium is effluent aqueous mediumfrom whichever of (a), (b), (c), and (d) that had (i), (ii), or (iii)added thereto in A).

In preferred embodiments of this invention, the microbiocide used is oneor more water-soluble 1,3-dibromo-5,5-dialkylhydantoins in which one ofthe alkyl groups is a methyl group and the other is an alkyl groupcontaining from 1 to about 4 carbon atoms, with1,3-dibromo-5,5-dimethylhydantoin being the most preferred of all.

Additional embodiments of this invention comprise apparatus forprocessing poultry for food in a plurality of processing operations,wherein the apparatus comprises at least (a) a scalding vessel orstation in which feathered poultry carcasses are contacted with a hotaqueous medium, (b) picker apparatus or de-feathering station in whichfeathers are removed from said carcasses, (c) eviscerating apparatus oran eviscerating station in which de-feathered carcasses are eviscerated,(d) inside-outside bird washing apparatus or station wherein the insidesand the outsides of eviscerated poultry carcasses are cleansed with oneor more streams of an aqueous medium, (e) a continuous online processingoperation or station wherein both the inside and the outside of thecarcass are sprayed, or an offline reprocessing operation wherein boththe inside and the outside of the carcass are sprayed, (f) optionally,at least one pre-chill spray cabinet or station wherein poultrycarcasses are sprayed with aqueous medium, (g) at least one chill tankor vessel in which poultry carcasses are immersed in cold aqueousmedium, and (h) optionally, a post-chill dip or spray apparatus orstation in which poultry carcasses from the chill tank are rinsed withcold aqueous medium, wherein:

-   A) at least one aqueous liquid medium input apparatus or device    adapted to provide to at least one apparatus or station downstream    from said scalding vessel or station, an aqueous medium containing    an effective microbial inhibiting amount of active bromine resulting    from the addition to said medium of (i) at least one    1,3-dihalo-5,5-dialkylhydantoin in which both of the halo atoms are    bromine atoms and one of the alkyl groups is a methyl group and the    other is a C₁₋₄ alkyl group or (ii) at least one    1,3-dihalo-5,5-dialkylhydantoin in which one of the halo atoms is a    bromine atom and the other is a chlorine atom, and both alkyl groups    are, independently, C₁₋₄ alkyl groups, or (iii) both of (i) and    (ii);-   B) at least one aqueous liquid medium-carrying system or apparatus    adapted to carry and transmit to said scalding vessel or station,    aqueous liquid medium effluent from at least one apparatus or    station in which said effluent contains bromine residue remaining    from input from the liquid medium input apparatus or device of A),    said at least one apparatus or station being downstream from said    scalding vessel or station; and-   C) at least one aqueous liquid medium carrying system or apparatus    adapted to carry and transmit effluent from said scalding vessel or    station to a waste water treatment or purification facility adapted    to utilize microbial action to reduce the biochemical oxygen demand    of waste water resulting from the processing of the poultry for    food.

In preferred embodiments of the above apparatus, the at least oneaqueous liquid medium-carrying system or apparatus in B) is disposed orconnected so as to be adapted to carry and transmit to the scaldingvessel or station, aqueous liquid medium effluent from at least oneapparatus or station to which (i), (ii), or (iii) is adapted to beprovided in A).

The above and other embodiments and features of this invention will bestill further apparent from the ensuing description, accompanyingdrawings, and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram showing the poultry processing operations of atypical processing line in a facility processing poultry for food andillustrating various preferred recycling operations made possible bythis invention to achieve the advantageous results made possible by thisinvention.

FIG. 2 is a block diagram showing the poultry processing operations ofanother typical processing line in a facility processing poultry forfood and illustrating various preferred recycling operations madepossible by this invention to achieve the advantageous results madepossible by this invention.

FURTHER DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

In typical poultry processing operations the sequence of operationscomprises killing the birds (usually after stunning them), scalding thefeathered poultry carcasses in a scalder or scalding tank, defeatheringthe carcasses (usually in a picker device), eviscerating the carcasses,subjecting eviscerated carcasses to inside-outside washing, subjectingeviscerated carcasses to continuous online processing or to certainoffline reprocessing of carcasses, optionally subjecting the carcassesto prechill spray (typically in a spray cabinet), chilling the carcassesin a chill tank filled with a cold aqueous medium, and optionallysubjecting the carcasses to a post-chill dip or spray. Other operationssuch as cold storage, etc., are also frequently used. In many of theseoperations, water is used either for washing or for serving as a contactmedium for chilling and/or for applying an aqueous microbiocidalsolution to the bird and/or carcass. Ordinarily, the effluent water usedin a given operation is allowed or caused to be transmitted to a wastewater treating facility such a filtering operation to remove solids anda pond or large pool in which the liquid effluent is subjected tomicrobial action in order to reduce the BOD of the water prior to itsrelease into the environment.

As noted above, a microbiocide is used pursuant to this invention. Onesuitable type is one or more N,N=-bromochloro-5,5-dialkylhydantoins inwhich both of the alkyl groups are, independently, alkyl groupscontaining from 1 to about 4 carbon atoms. For convenience, this type ofN,N=-bromochloro-5,5-dialkylhydantoins is sometimes referred tocollectively herein as ABCDAH@.

Non-limiting examples of suitable compounds of this type include, forexample, such compounds as 1,3-dichloro-5,5-dimethylhydantoin,1,3-dichloro-5,5-diethylhydantoin, 1,3-dichloro-5,5-di-n-butylhydantoin,1,3-dichloro-5-ethyl-5-methylhydantoin,N,N′-bromochloro-5,5-dimethylhydantoin,N,N′-bromochloro-5-ethyl-5-methylhydantoin,N,N′-bromochloro-5-propyl-5-methylhydantoin,N,N′-bromochloro-5-isopropyl-5-methylhydantoin,N,N′-bromochloro-5-butyl-5-methylhydantoin,N,N′-bromochloro-5-isobutyl-5-methylhydantoin,N,N′-bromochloro-5-sec-butyl-5-methylhydantoin,N,N′-bromochloro-5-tert-butyl-5-methylhydantoin,N,N′-bromochloro-5,5-diethylhydantoin, and mixtures of any two or moreof the foregoing. N,N′-bromochloro-5,5-dimethylhydantoin is availablecommercially under the trade designation Bromicide® biocide (Great LakesChemical Corporation). Another suitable bromochlorohydantoin mixture iscomposed predominantly of N,N′-bromochloro-5,5-dimethylhydantointogether with a minor proportion by weight of1,3-dichloro-5-ethyl-5-methylhydantoin. A mixture of this latter type isavailable in the marketplace under the trade designation Dantobrom®biocide (Lonza Corporation). Of such products,N,N=-bromochloro-5,5-dimethylhydantoin is a preferred material becauseof its commercial availability and its suitability for use in thepractice of this invention.

The designation N,N′ in reference to, say,N,N′-bromochloro-5,5-dimethylhydantoin means that this compound can be(1) 1-bromo-3-chloro-5,5-dimethylhydantoin, or (2)1-chloro-3-bromo-5,5-dimethylhydantoin, or (3) a mixture of1-bromo-3-chloro-5,5-dimethylhydantoin and1-chloro-3-bromo-5,5-dimethylhydantoin. Also, it is conceivable thatsome 1,3-dichloro-5,5-dimethylhydantoin and1,3-dibromo-5,5-dimethylhydantoin could be present in admixture with(1), (2), or (3).

Another suitable and more preferred type of microbiocide for use in thepractice of this invention is one or more1,3-dibromo-5,5-dialkylhydantoins in which one of the alkyl groups is amethyl group and the other is an alkyl group containing from 1 to about4 carbon atoms. For convenience, this type of1,3-dibromo-5,5-dialkylhydantoins is sometimes referred to collectivelyherein as ADBDAH@.

The above preferred 1,3-dibromo-5,5-dialkylhydantoins biocides areexemplified by 1,3-dibromo-5,5-dimethylhydantoin,1,3-dibromo-5-ethyl-5-methylhydantoin,1,3-dibromo-5-n-propyl-5-methylhydantoin,1,3-dibromo-5-isopropyl-5-methylhydantoin,1,3-dibromo-5-n-butyl-5-methylhydantoin,1,3-dibromo-5-isobutyl-5-methylhydantoin,1,3-dibromo-5-sec-butyl-5-methylhydantoin,1,3-dibromo-5-tert-butyl-5-methylhydantoin, and mixtures of any two ormore of them. Of these biocidal agents,1,3-dibromo-5-isobutyl-5-methylhydantoin,1,3-dibromo-5-n-propyl-5-methylhydantoin, and1,3-dibromo-5-ethyl-5-methylhydantoin are, respectively, preferred, morepreferred, and even more preferred members of this group from the costeffectiveness standpoint. Of the mixtures of the foregoing biocides thatcan be used pursuant to this invention, it is preferred to use1,3-dibromo-5,5-dimethylhydantoin as one of the components, with amixture of 1,3-dibromo-5,5-dimethylhydantoin and1,3-dibromo-5-ethyl-5-methylhydantoin being particularly preferred.1,3-Dibromo-5,5-dimethylhydantoin is especially preferred because of itssuperior microbiocidal effectiveness, its ready availability in themarketplace, and its suitability for use in the practice of thisinvention. This compound is available in the marketplace in tablet orgranular form under the trade designations XtraBrom® 111 biocide andXtraBrom® 111 T biocide (Albemarle Corporation).

For convenience, in the present disclosure, the above microbiocides areoften referred to in the singular or plural as Athe presentmicrobiocidal agent@ or Athe present microbiocidal agents@ as the casemay be. The term Athe present microbiocidal agent(s) refers to bothsingular and plural. Also, the term “active bromine@ or Aactivechlorine@ is the halogen residual that exists in the water upondissolving in water the particular microbiocidal agent under discussion.The term Aactive halogen@ means Aactive bromine@ or Aactive chlorine@ orboth, depending upon the context in which the term is used.

Methods for producing the present microbiocidal agent(s) are known andreported in the literature.

When the present microbiocidal agent(s) is (i) a mixture of two or moreindividual N,N′-bromochloro-5,5-dialkylhydantoins of the types referredto above, (ii) a mixture of two or more individual1,3-dibromo-5,5-dialkylhydantoins of the type referred to above, or(iii) a mixture of one or more individualN,N′-bromochloro-5,5-dialkylhydantoins of the type referred to above andone or more individual 1,3-dibromo-5,5-dialkylhydantoins of the typereferred to above, the components of the mixture can be in anyproportions relative to each other.

One of the features of this invention is the discovery that the bromineresidues in water resulting from the addition thereto of the presentmicrobiocidal agent(s) are substantially less thermally stable than thechlorine residues resulting from the addition to water of sodiumhypochlorite, a microbiocide that is widely used in water used in theprocessing of poultry for food. Indeed, the bromine residues in waterresulting from the addition thereto of the present microbiocidal agentare substantially less thermally stable than the bromine residues from asulfamate-stabilized bromine-based microbiocide formed by interaction inwater of bromine chloride and sulfamic acid or a water soluble sulfamatesalt, a highly effective, commercially available microbiocide.

As a consequence of this discovery, the present microbiocidal agent(s)when added downstream from the scalding operation produces activebromine which can exert its microbiocidal effectiveness in controllingmicroorganisms in the downstream operation(s) to which the presentmicrobiocidal agent(s) has/have been added. Furthermore, instead ofsending the bromine-residual-containing effluent aqueous medium fromsuch downstream operation(s) to the waste water treating facility wherea considerable amount of the microorganisms in the BOD operation aredestroyed by the bromine residues in the effluent, pursuant to thisinvention the bromine-residual-containing effluent aqueous medium fromone or more such downstream operations is recycled to the scaldingoperation. This, in turn, provides the following dual benefits: First, asignificant portion of the bromine residues from the presentmicrobiocidal agent(s) is/are thermally decomposed at the elevatedtemperatures existing in the scalding water. Thus, on transferring theeffluent from the scalding operation to the BOD reducing operation, theamount of microorganism destruction occurring in the BOD reducingoperation is significantly reduced as compared to that which would occurfrom the transfer to the BOD reducing operation of the effluent from oneor more of the downstream operations containing the original bromineresidues. Secondly, the recycle of the effluent from the downstreamoperations containing the original bromine residues to the scaldingoperation reduces the amount of water used in the overall processing ofthe poultry for food. Thus, when adding the present microbiocidalagent(s) to more than one downstream operation, it is preferred torecycle the effluents from all of the downstream operations in which thepresent microbiocidal agent(s) was/were employed because this increasesthe amount of water that is recycled to and through the scaldingoperation and thus reuses this larger quantity of water before disposal.Note also that the effluent recycled to and through the scaldingoperation contributes microbiocidal action to the feathered carcasses inthe scalding operation.

The aqueous microbiocidal solutions used in this invention can be formedin many cases by adding one or more of the present microbiocidal agentsin undiluted finely divided or powdery form to water being used or to beused in one or more poultry processing operations located downstreamfrom the scalding operation. Alternatively, water flowing to a poultryprocessing operation located downstream from the scalding operation canbe pre-contacted in a feeding device containing granular, nugget,pellet, tablet or other non-powdery particulate form of one or more ofthe present microbiocidal agents disposed in a canister, tank, or othersimilar vessel.

If desired, the present microbiocidal agent(s) can be dissolved in asuitable innocuous, harmless, water-soluble organic solvent with orwithout water to form a solution which can be added to the waterutilized at one or more appropriate downstream processing operations ofthe poultry processing process. One such innocuous, harmless,water-soluble organic solvent, which non-toxic, at least at the dosagelevels involved, such is acetonitrile.

By virtue of the recycle pursuant to this invention, feathered poultrycarcasses which are contacted with a hot aqueous solution which containsa residual microbial inhibiting amount of active bromine. The contactbetween the hot aqueous solution and the feathered poultry carcass (a)facilitates subsequent defeathering of the carcasses, (b) controlscontamination of the carcasses by microorganisms, (c) reduces the amountof halogen residual in the hot aqueous solution.

The amount (concentration) of the selected microbiocide utilized in thepractice of this invention will vary depending on various factors suchas the particular microbiocide being used, the nature and frequency ofprior microbiocidal treatments, the types and nature of themicroorganisms present, the amount and types of nutrients available tothe microorganisms, the nature and extent of cleansing actions, if any,taken in conjunction with the microbiocidal treatment, the surface orlocus of the microorganisms being treated, and so on. In any event, amicrobiocidally-effective amount of the aqueous solution of themicrobiocide of this invention will be applied to or contacted with themicroorganisms. In the case of DBDAH, typically the diluted solutionwill contain a microbiocidally-effective amount of active halogen,measured as bromine, in the range of about 2 to about 600 ppm (wt/wt),preferably in the range of about 2 to about 300 ppm (wt/wt), and morepreferably in the range of about 5 to about 100 ppm (wt/wt), activehalogen being determinable by use of the conventional DPD testprocedure. In the case of BCDAH, the corresponding ranges are about 2 toabout 1000 ppm (wt/wt), preferably about 2 to about 600 ppm (wt/wt) andmore preferably about 8 to about 200 ppm (wt/wt) as active bromine. Ifthe actual active halogen in the solution consists of active chlorine,the concentration of the diluted solution used is preferably at leasttwo to three times higher than the minimums of the foregoing ranges. Inthe case of the 1,3-dibromo-5,5-dialkylhydantoins used pursuant to thisinvention, a particularly preferred range for use is in the range ofabout 5 to about 70 ppm (wt/wt) of active bromine. When contactingpoultry carcasses or edible parts thereof with aqueous solutions formedfrom at least one 1,3-dibromo-5,5-dialkylhydantoin used pursuant to thisinvention, it is especially preferred to use in the water for washing orotherwise contacting the poultry carcasses or edible parts thereof, amicrobiocidally effective amount of active bromine that does notsignificantly or appreciably bleach the skin of the carcass or have asignificant or appreciable adverse effect upon the taste of cooked meatfrom the poultry such as the breast meat and thigh meat. Such amount istypically within the range of about 0.5 to about 150 ppm (wt/wt) or whensmaller amounts are used, within the range of about 0.5 to about 100 ppm(wt/wt) of active bromine as determinable by the DPD test procedure. Itwill be understood that departures from the foregoing ranges can be madewhenever deemed necessary or desirable, and such departures are withinthe spirit and scope of this invention.

Referring now to the drawings, which are illustrative but notrestrictive, the block diagram of FIGS. 1 and 2 illustrate theapparatus, equipment, devices and/or stations through which the poultrytypically pass during the processing operation. Thus, the downwardlydirected successive lines from 10 to 12 to 14 to 16, etc., illustrate atypical flow path of the poultry from stage to stage or operation tooperation. It will be appreciated that the Drawings relate both tohighly automated processing lines as exist in high speed, highproduction processing facilities, and to processing operation infacilities wherein some of the operations are conducted by use ofhand-held equipment such as hand-held sprays.

In the systems depicted in FIGS. 1 and 2, the first operation shown, 10,comprises apparatus or facilities in which the birds are stunned andkilled. This is followed by scalding vessel or tank 12 in which thefeathered birds are contacted with hot aqueous medium in order to loosenthe feathers, picker apparatus or station 14 where feathered birds from12 are defeathered such as by beaters or other means to rid the carcassof the loosened feathers, and evisceration apparatus or station 16 wherethe carcasses are opened and the viscera removed, either automaticallyor manually. The next apparatus or facility shown is an inside-outsidebird washing (IOBW) facility 18 where the open carcasses are washed withaqueous sprays, typically suitably powerful aqueous jet sprays, thewashing again taking place either in automated mechanical facilities orby use of hand-held sprays. The sprayed carcasses are then passed eitherto a continuous on-line processing facility or station (COP) 20 (seeFIG. 1) or when needed, to off-line reprocessing facility or station 21(see FIG. 2). Next, the carcasses optionally are passed to prechillspray apparatus or a prechill spray facility 22 in which a spray ofaqueous medium is applied to the carcasses to remove residues from anyprior operation and in some cases to reduce their temperature. Fromapparatus or facility 22, if used, or from facility or station 20 or 21,the carcasses are passed into a chill tank or other chilling vessel 24in which they remain for a sufficient period of time to becomethoroughly chilled. Optionally, the chilled carcasses are then subjectedto post-chill dip or spray apparatus or facilities 26 where residuesremaining on the carcasses are rinsed away by contact with a bath and/orsprays of water.

In FIG. 2, the flow path of the poultry carcasses from IOBW facility 18as shown either leads directly to prechill spray facility 22 or first tooff-line reprocessing facility or station 21 and thence to prechillspray facility 22. This illustrates the fact that governmentalregulations, at least in the United States, require that if thecarcasses from IOBW facility 18 carry residual fecal matter or the like,the carcasses must go to facility or station 21 where the contaminationis removed by appropriate spraying means. The so-cleansed carcasses thenproceed to prechill spray facility 22. On the other hand, if thecarcasses from IOBW facility 18 are not so-contaminated, they canproceed directly to prechill spray facility 22.

Pursuant to this invention, a microbiocidal quantity of the presentmicrobiocidal agent(s) is/are provided in any appropriate way to thewater entering and/or to be used in any facility, apparatus, device,station, or operation downstream from scalding vessel or tank 12.Preferably, the present microbiocidal agent(s) is/are provided in anysuitable way to the water entering and/or to be used in inside-outsidebird washing (IOBW) facility 18, or to continuous on-line processingfacility or station 20 or to off-line reprocessing facility or station21, or to prechill spray apparatus or prechill spray facility 22, ifused. Also pursuant to this invention, aqueous effluent from anyfacility, apparatus, device, station, or operation downstream from theplace where a microbiocidal quantity of the present microbiocidalagent(s) is/are provided, is recycled to scalding vessel or tank 12wherein the present microbiocidal agent(s) typically contribute(s)microbiocidal activity while also undergoing at least partial thermaldecomposition. In the preferred embodiments depicted, the recycles shownare effluents from an inside-outside bird washing (IOBW) facility 18, orfrom a continuous on-line processing facility or from station 20 or froman off-line reprocessing facility or station 21, or from prechill sprayapparatus or prechill spray facility 22, if used, or any combination oftwo or more of these. Such recycle streams are represented schematicallyin FIG. 1 by lines 30, 32, 34, and in FIG. 2 by lines 40, 42, 44. Itwill be appreciated that any such line can be directly attached eitherto one or more such facilities or stations themselves or from aneffluent line extending from one or more of these facilities orstations.

Effluent from scalding vessel or tank 12 is passed or allowed to pass toa waste water purification operation 36 wherein microbial action isutilized to reduce the biochemical oxygen demand of this effluentwhether by itself or in combination with effluent waste water from otherstages or operations in the overall poultry processing process. Aftertreatment in waste water purification operation 36, the treated wastewater is released to the environment as indicated by line 55. It will beappreciated that in typical poultry processing facilities effluent wastewater from various individual stages are also passed or allowed to passto waste water purification operation 36 either as individual streams ormore commonly as an overall combined stream into which waste watereffluent from scalding vessel or tank 12 is passed or allowed to pass.Thus, line 50 should not be construed as requiring a separate line fromscalding vessel or tank 12 to waste water purification operation 36.Instead, line 50 merely represents the fact that waste water fromscalding vessel or tank 12, whether by itself in a separate line or in amixture of waste water effluents emanating from other stages in theprocessing line, is sent to water purification operation 36.

There are two different types of procedures that are used fordetermining active halogen content, whether active chlorine, activebromine or both. For measuring concentrations in the vicinity of aboveabout, say, 1000 ppm or so (wt/wt) of active bromine or, say, aboveabout 500 ppm of active chlorine, starch-iodine titration is thepreferred procedure. On the other hand, where concentrations are belowlevels in these vicinities, the conventional DPD test procedure is moresuitable, as this test is designed for measuring very low active halogenconcentrations, e.g., active chlorine concentrations in the range offrom zero to about 5 ppm (wt/wt) or active bromine concentrations in therange of from zero to about 10 ppm (wt/wt). In fact, where the actualconcentration of active chlorine is between, say, about 5 ppm and about500 ppm (wt/wt), or where the actual concentration of active bromine isbetween, say, about 10 ppm and about 500 ppm (wt/wt), the test sample istypically diluted with pure water to reduce the actual concentration tobe in the range of about 1 to about 5 ppm in the case of active chlorineand to be in the range of about 1 to about 10 ppm in the case of activebromine before making the DPD analysis. It can be seen therefore thatwhile there is no critical hard-and-fast concentration dividing linebetween which procedure to use, the approximate values given aboverepresent a practical approximate dividing line, since the amounts ofwater dilution of more concentrated solutions when using the DPD testprocedure increase with increasing initial active halogen concentration,and such large dilutions can readily be avoided by use of starch-iodinetitration when analyzing the more concentrated solutions. In short, withsuitably dilute solutions use of the DPD test procedure is recommended,and with more concentrated solutions use of starch-iodine titration isrecommended.

The starch-iodine titration procedure for determination of activehalogen has long been known. For example, chapter XIV of Willard-Furman,Elementary Quantitative Analysis, Third Edition, D. Van NostrandCompany, Inc., New York, Copyright 1933, 1935, 1940 provides adescription of starch-iodine titration. While details of standardquantitative analytical procedures for determination of active halogenin such product solutions by starch-iodine titration may vary from caseto case, the results are normally sufficiently uniform from one standardprocedure to another as not to raise any question of unreliability ofthe results. A recommended starch-iodine titration procedure is asfollows: A magnetic stirrer and 50 milliliters of glacial acetic acidare placed in an iodine flask. The sample (usually about 0.2-0.5 g) forwhich the active halogen is to be determined is weighed and added to theflask containing the acetic acid. Water (50 milliliters) and aqueouspotassium iodide (15%, wt/wt; 25 milliliters) are then added to theflask. The flask is stoppered using a water seal. The solution is thenstirred for fifteen minutes, after which the flask is unstoppered andthe stopper and seal area are rinsed into the flask with water. Anautomatic buret (Metrohm Limited) is filled with standardized 0.1 normalsodium thiosulfate. The solution in the iodine flask is titrated withthe 0.1 normal sodium thiosulfate; when a faint yellow color isobserved, one milliliter of a 1 wt % starch solution in water is added,changing the color of the solution in the flask from faint yellow toblue. Titration with sodium thiosulfate continues until the blue colordisappears. The amount of active halogen is calculated using the weightof the sample and the volume of sodium thiosulfate solution titrated. Inthis way, the amount of active halogen such as active chlorine or activebromine in an aqueous product solution, regardless of actual chemicalform, can be quantitatively determined.

The standard DPD test for determination of low levels of active halogenis based on classical test procedures devised by Palin in 1974. See A.T. Palin, “Analytical Control of Water Disinfection With SpecialReference to Differential DPD Methods For Chlorine, Chlorine Dioxide,Bromine, Iodine and Ozone”, J. Inst. Water Eng., 1974, 28, 139. Whilethere are various modernized versions of the Palin procedures, therecommended version of the test is fully described in Hach WaterAnalysis Handbook, 3rd edition, copyright 1997. The procedure for “totalchlorine” (i.e., active chlorine) is identified in that publication asMethod 8167 appearing on page 379, Briefly, the “total chlorine” testinvolves introducing to the dilute water sample containing activehalogen, a powder comprising DPD indicator powder, (i.e.,N,N′-diethyldiphenylenediamine), KI, and a buffer. The active halogenspecies present react(s) with KI to yield iodine species which turn theDPD indicator to red/pink. The intensity of the coloration depends uponthe concentration of “total chlorine” species (i.e., active chlorine”)present in the sample. This intensity is measured by a colorimetercalibrated to transform the intensity reading into a “total chlorine”value in terms of mg/L as Cl₂. If the active halogen present is activebromine, the result in terms of mg/L as Cl₂ is multiplied by 2.25 toexpress the result in terms of mg/L as Br₂ of active bromine.

In greater detail, the DPD test procedure is as follows:

-   1. To determine the amount of species present in the water which    respond to the “total chlorine” test, the water sample should be    analyzed within a few minutes of being taken, and preferably    immediately upon being taken.-   2. Hach Method 8167 for testing the amount of species present in the    water sample which respond to the “total chlorine” test involves use    of the Hach Model DR 2010 colorimeter. The stored program number for    chlorine determinations is recalled by keying in “80” on the    keyboard, followed by setting the absorbance wavelength to 530 nm by    rotating the dial on the side of the instrument. Two identical    sample cells are filled to the 10 mL mark with the water under    investigation. One of the cells is arbitrarily chosen to be the    blank. To the second cell, the contents of a DPD Total Chlorine    Powder Pillow are added. This is shaken for 10-20 seconds to mix, as    the development of a pink-red color indicates the presence of    species in the water which respond positively to the DPD “total    chlorine” test reagent. On the keypad, the SHIFT TIMER keys are    depressed to commence a three minute reaction time. After three    minutes the instrument beeps to signal the reaction is complete.    Using the 10 mL cell riser, the blank sample cell is admitted to the    sample compartment of the Hach Model DR 2010, and the shield is    closed to prevent stray light effects. Then the ZERO key is    depressed. After a few seconds, the display registers 0.00 mg/L Cl₂.    Then, the blank sample cell used to zero the instrument is removed    from the cell compartment of the Hach Model DR 2010 and replaced    with the test sample to which the DPD “total chlorine” test reagent    was added. The light shield is then closed as was done for the    blank, and the READ key is depressed. The result, in mg/L Cl₂ is    shown on the display within a few seconds. This is the “total    chlorine” level of the water sample under investigation.

In the practice of this invention the microbiocidal system can be usedin various ways. For example, a microbiocidally effective amount of amicrobiocide of this invention is applied to the locus of themicroorganisms to be eradicated or controlled so that the microbiocidalsystem comes in contact with these microorganisms. The application canbe made by thorough application by pouring, spraying, wet mopping,flooding, and/or wet wiping infested or potentially infested surfaces orareas of the processing equipment and environs such as flooring, walls,tables, conveyors, stanchions, conduits, tanks, and drains with abiocidally-effective amount of an aqueous solution of the microbiocide.Where applicable and possible, portions of the processing apparatus canbe immersed in an aqueous solution of the microbiocide, with temporarydisassembly, if necessary. Such applications should be conductedroutinely on a frequency sufficient to ensure that exposure of thepoultry being processed to dangerous microorganisms, such as bacteriaand biofilms is prevented to the greatest extent possible. For bestresults these operations should be conducted in conjunction orassociation with thorough cleaning operations such as scrubbing,scouring, scraping and, otherwise removing infestations of biofouling orbiofilms, whether visible or invisible. After contacting themicroorganisms with the microbiocide for a suitable period of time toensure penetration into polysaccharide slimes and other defensemechanisms of various species of these microorganisms, the entiredisinfected area should be washed, e.g., hosed down, with clean waterand preferably the washings themselves should be disinfected withadditional microbiocide of this invention before discharge. The contacttimes will of course vary depending upon the frequency and thoroughnessof the cleaning and disinfection operations and the identity andconcentration of the particular microbiocidal solution being employed.Generally speaking contact times may fall in the range of from about afew minutes to a few hours, but any period of time that effects theeradication or control of the microbial population in the poultryprocessing areas should be used and is within the scope of thisinvention.

Another mode of applying the microbiocidally-effective amounts ofsolid-state microbiocides of these embodiments of the invention is tocause the microbiocide to be leached into water streams passing throughconduits and into tanks or other washing devices utilized in theprocessing of the poultry. For example, suitable solid forms of themicrobiocide such as tablets, briquettes, pellets, nuggets, or granulesare placed in suitable feeding devices through which a stream of wateris passed. The passage of the water through the bed of the microbiocideresults in the stream continuously dissolving small quantities of themicrobiocide to thereby provide microbiocidally effective amounts of themicrobiocide in the water. 1,3-Dibromo-5,5-dimethylhydantoin isespecially preferred for use in this mode of application because of itsrelatively low solubility and its very high microbiocidal effectivenesseven at low concentrations. The relatively low water solubility of1,3-dibromo-5,5-dimethylhydantoin thus provides a relatively slow rateof dissolution in water at ambient room temperatures. This translatesinto relatively long periods of use before need of refilling the deviceholding the solids. By way of example, the solubility of1,3-dibromo-5,5-dimethylhydantoin in water at 75 EF (ca. 24 EC) is 405ppm expressed as Cl₂ whereas the solubilities ofN,N′-bromochloro-5,5-dimethylhydantoin and of the commercial mixture ofN,N′-bromochloro-5,5-dimethylhydantoin and1,3-dichloro-5-ethyl-5-methylhydantoin at the same temperature are,respectively, 890 ppm and 1905 ppm, both expressed as Cl₂.

An especially cost-effective, operationally efficient, and highlypreferred way of forming aqueous microbiocidal solutions of one or more1,3-dibromo-5,5-dialkylhydantoins in which one of the alkyl groups is amethyl group and the other alkyl group contains in the range of 1 toabout 4 carbon atoms, most preferably 1,3-dibromo-5,5-dimethylhydantoin,(“dibromodialkylhydantoin(s)”) comprises passing water through a bed ofone or more such dibromodialkylhydantoin(s) in granular, nugget, pellet,tablet or other non-powdery particulate form (“bed”) disposed in acanister, tank, or other similar vessel (“tank”). Preferably the tankhas a pressure sealable port at its upper portion for periodicallyreplenishing the contents of the bed, and the water is caused to flowupwardly through a portion of the bed. More preferably, the tank iselongated in an upward direction so that the bed is longer from top tobottom than from side to side, this upward water flow is dispensed intothe bed to flow upwardly through only a lower portion of the bed, andthence substantially horizontally through a port disposed between thelower and the upper portions of the bed and tank. In this way the upperportion of the bed serves as a reserve supply of contents of the bedwhich automatically feeds into the lower portion of the bed undergravity as the lower portion of the bed is slowly but substantiallyuniformly dissolved away in the water flow. Thus in this operation thewater flow is preferably at least a substantially continuous flow, andmost preferably, is a continuous flow. Methods for producing granules,tablets or other non-powdery particulate forms of1,3-dibromo-5,5-dimethylhydantoin are described in detail incommonly-owned copending applications PCT/US 01/01541, 01/01545, and01/01585, all filed Jan. 17, 2001, each claiming priority based onrespective earlier-filed corresponding U.S. applications. Excellentprocess technology for producing 1,3-dibromo-5,5-dimethylhydantoin foruse in making such granules, tablets or other non-powdery particulateforms is described in detail in commonly-owned copending applicationPCT/US 01/01544, filed Jan. 17, 2001, claiming priority based on anearlier-filed corresponding U.S. application. The disclosures of eachsuch PCT and U.S. application is incorporated herein by reference.Particularly preferred apparatus for use in conjunction with suchgranules, tablets or other non-powdery particulate forms of thesedibromodialkylhydantoin(s) in forming aqueous microbiocidal solutionsthereof is available from Neptune Chemical Pump Company, a division ofR.A. Industries, Inc., Lansdale, Pa. 19446, as “Bromine Feeders” ModelsBT-15, BT-40, BT-42, BT-80, BT-160, BT-270, and BT-350, or equivalent.Excellent results are achieved using combinations of Model BT-40 withgranules or nuggets of 1,3-dibromo-5,5-dimethylhydantoin (XtraBrom® 111biocide) available from Albemarle Corporation. Single charges of suchmicrobiocides in tablet or granular form in such device can providecontinuous highly-effective microbiocidal activity in bodies of end usewater at ordinary outdoor temperatures for as long as five (5) monthswithout need for replenishment.

Another suitable method of effecting contact between the microbiocideand the microorganisms is to pump an aqueous solution containing amicrobiocidally-effective amount of the microbiocide through theconduits and into the tanks or other washing devices, such as scaldingtanks and chill tanks, utilized in the processing of the poultry.Variants of this procedure include dispensing portion-wise as by gravitydripping an aqueous solution of the microbiocide directly into a tank orother vessel in which poultry are to be or are being processed.

Preferably two or more of the foregoing methods of application of themicrobiocides of this invention are used. Thus in a preferred embodimenta microbiocide of these embodiments of the invention is applied by (i)periodically contacting at least portions, if not all, of the poultryprocessing apparatus to disinfection or sanitization with amicrobiocidally-effective amount of an aqueous solution of at least oneof the above 1,3-dibromo-5,5-dialkylhydantoins, and (ii) contacting theexposed surfaces of the poultry with a microbiocidally-effective amountof an aqueous solution of at least one of the above1,3-dibromo-5,5-dialkylhydantoins, before and/or after, preferablyafter, dispatching the fowl, and most preferably after defeathering thefowl. In another preferred embodiment, a microbiocide of theseembodiments of the invention is applied by (i) periodically contactingat least portions, if not all, of the poultry processing apparatus todisinfection or sanitization with a microbiocidally-effective amount ofan aqueous solution of at least one the above1,3-dibromodialkylhydantoins, and (ii) contacting the edible portionsand/or internal organs of the dispatched fowl with amicrobiocidally-effective amount of an aqueous solution of at least oneof the above 1,3-dibromo-5,5-dialkylhydantoins.

Particularly preferred processes of this invention are those wherein thefowl are processed by a series of steps which comprise the following:(a) suspending the fowl in moving clamps or shackles, (b) stunning, butnot killing, the fowl such as by use of a suitable gas, or by contactingat least the heads of the fowl with a water-applied electric shock tostun the fowl, e.g., by immersing the heads in a water bath carrying asuitable current to effect the stunning, (c) cutting the jugular veinsand/or carotid arteries at the neck of the stunned fowl either manuallywith a knife or automatically with a mechanical cutting device, (d)draining blood from the carcasses, (e) scalding the birds with hotwater, e.g., in a scalding tank, to facilitate feather removal, (f)defeathering the fowl, (g) removing the heads and feet from the fowl,(h) eviscerating the fowl either manually with a knife, or automaticallywith mechanical evisceration apparatus, (i) separating the viscera fromthe carcasses, (j) washing the carcasses, and (k) chilling thecarcasses, e.g., in water such as by passage of the carcasses through atleast one and often two chill tanks, or by air chilling. The scaldingstep will typically be conducted at water temperatures in the range ofabout 50 to about 65 EC, with the lower temperatures being preferred forretention of normal yellow-colored skin. The higher temperatures willmore usually be used in connection with turkeys and spent egg-layerhens. The chilling temperatures used will typically reduce the carcasstemperature to below about 4 EC, with final temperatures of the finishedcarcasses for shipment being as low as about −2 EC. Other steps can beincluded and in some cases one or more of the steps (a) through (j) maybe altered or revised or the sequence of the steps may to some extent bealtered or revised, to adapt to given circumstances. Examples of extrasteps that may be included are inspection steps, e.g., by governmentalregulatory personnel, and wax-dipping in the case of water fowl toenhance the extent of defeathering. Inspections are often conductedsubsequent to the evisceration step, such as before separating theviscera from the carcasses. Wax dipping will typically be used whenprocessing waterfowl, the feathers of which typically are more difficultto remove than, say, chickens. Wax dipping will typically be performeddirectly after use of feather-picking machines which utilize rubber“fingers” to beat off the feathers. The wax dipping step will typicallyinvolve dipping the partially defeathered carcass into a molten waxcontained in a tank, allowing the wax to harden on the carcass, and thenremoving the wax coating as by peeling it off along with feathersembedded in the wax. This operation can be repeated as desired, beforeproceeding to the next step in the process, e.g., removal of the headsand feet. One illustrative example of a suitable revision of thesequence of steps, would be to conduct step (g) before step (d) insteadof after step (f). Upon a reading of this disclosure, other suitablesequence revisions may well become obvious to one of ordinary skill inthe art, and thus need not be further elaborated upon here.

In the above processing, the microbiocidal action of the microbiocidesof these embodiments of the invention, preferably one or more applicablebromine-based microbiocides used pursuant to this invention, can beapplied at any of a variety of suitable stages in the operation. Forexample, an applicable microbiocidal solution of this invention can beapplied to any or all of the processing equipment used including knives,conveying apparatus, the surfaces of emptied scaling tanks, defeatheringapparatus, (e.g., rubber “fingers” etc.), knives and mechanicalapparatus used for cutting or eviscerating the fowl, all surfaces thatcome in contact with the blood or the viscera of the fowl, includingtables, conveyor belts, etc., and all surfaces that come in contact withthe carcasses after separation of the viscera therefrom. The applicablesanitizing solutions of this invention can be applied to by immersion,spraying, flooding, or any other way of ensuring that themicrobiocidally-effective solution contacts the surfaces that contain orare exposed to the undesirable microorganisms such as bacteria and/orbiofilm (biofouling).

Automated dispensing equipment suitable for use in dispensing themicrobiocides of this invention has been described in the literature andto at least some extent is available in the marketplace. For a referenceto such equipment, see for example U.S. Pat. No. 5,683,724 wherein anautomated dispensing system is described.

As noted above, the reduction in the amount of halogen residual in thehot aqueous solution appears to be caused in part by the low thermalstability in hot water of the solute formed in water on dissolving a1,3-dihalo-5,5-dialkylhydantoin in water. In fact, it has been found,quite surprisingly, that the solutes of 1,3-dibromo-5,5-dialkylhydantoinand of N,N=-bromochloro-5,5-dialkylhydantoin are significantly lessthermally stable in hot water than is the solute of the conventionalwidely-used chlorine-based microbiocide, sodium hypochlorite. Indeed,the solutes of 1,3-dibromo-5,5-dialkylhydantoin and ofN,N=-bromochloro-5,5-dialkylhydantoin were found to be less thermallystable than the stabilized bromine microbiocide produced from brominechloride and sulfamate anion (Stabrom® 909 biocide; AlbemarleCorporation).

In particular, experiments were carried out in which water at a pH of7.0 was heated to approximately 140 EF (60 EC) and then either (i)sodium hypochlorite, (ii) a concentrated alkaline aqueous solutionproduced from bromine chloride and sulfamate anion (Stabrom® 909biocide; Albemarle Corporation), for convenience referred to as SSBC,(iii) 1,3-dibromo-5,5-dimethylhydantoin, or (iv)N,N=-bromochloro-5,5-dimethylhydantoin was added to form a solution. Theresultant solutions were kept at the same temperature for extendedperiods of time while periodically taking samples to determine halogencontent as total chlorine in parts per million (wt/wt). The sameprocedure was carried out in which the water was kept at roomtemperature, this group of experiments serving as a control. The resultsof these experiments are summarized in Tables 1-4. In Table 1, thevalues given are ppm (wt/wt) of total chlorine in the solution. InTables 2, 3, and 4, the values given are ppm (wt/wt) of total bromine inthe solution.

TABLE 1 Control - Sodium Sodium Hypochlorite Hypochlorite Microbiocide,Microbiocide, Solution Held at Solution Held at Time Room Temperature140EF Initial 54 56 1 hour 55  1 hour, 40 minutes 52 2 hours 55 3 hours,25 minutes 52 21 hours 51.5 22.5 hours 54 47 hours 49 8 days 49

TABLE 2 Control SSBC Microbiocide, Solution Held at SSBC Microbiocide,Time Room Temperature Solution Held at 140EF Initial 105 108  3 hours,10 minutes 107  3 hours, 15 minutes 105  4 hours, 40 minutes 106 104  21hours, 55 minutes 105  22 hours 110 118 hours 107 99

TABLE 3 Control - 1,3-Dibromo-5,5- dimethylhydantoin 1,3-Dibromo-5,5-Microbiocide, dimethylhydantoin Solution Held at Microbiocide, SolutionTime Room Temperature Held at 140EF Initial 94 91   1 hour, 35 minutes98   2 hours, 20 minutes 78   4 hours, 20 minutes 95 65 22.5 hours 88 20  48 hours 68

TABLE 4 Control - N,N =- Bromochloro-5,5- dimethylhydantoin N,N =-Bromochloro- Microbiocide, 5,5-dimethylhydantoin Solution HeldMicrobiocide, Solution Time at Room Temperature Held at 140EF Initial 8293  1 hour, 55 minutes 77  2 hours, 5 minutes 68  3 hours, 55 minutes 74 4 hours, 5 minutes 58  6 hours, 55 minutes 54 23 hours, 30 minutes 6523 hours, 35 minutes 27

In the practice of this invention, it can prove useful to utilizecombinations of different sanitizing steps using different microbiocidalagents, at least one of which is a microbiocide of this invention, viz.,(i) at least one DBDAH, or (ii) at least one BCDAH, or (iii) both of (i)and (ii). For example, a microbiocide of this invention, preferably abromine-based microbiocide of (i) can be applied to or contacted withvarious surfaces associated with the poultry processing such asconduits, tanks (e.g., the scalding tank(s), chill tank(s), conveyorbelts or conveyor lines, and the poultry carcasses themselves can betreated with an antimicrobial agent such as solutions or gels containingcarboxylic acids (e.g., acetic or lactic acid) and/or peroxycarboxylicacids, such as peracetic acid, peroxyoctanoic acid, peroxydecanoic acid,or the like. Use of such carboxylic acids is described for example inU.S. Pat. No. 6,113,963. The result of such combined operations ishighly effective sanitization. In fact, it is contemplated that thiscombination of operations will result in a greater extent ofmicrobiological eradication than has been generally achievableheretofore, especially when the bromine-based biocide used is1,3-dibromo-5,5-dimethylhydantoin and the carboxylic acid used isperacetic acid. Indeed the combined effect of these microbiocides may besynergistic.

Another microbiocide which can be utilized in combined operationspursuant to this invention is trisodium phosphate a material whichaccording to Capita et al., Meat Science, 2000, 55 (4), 471-474, hasbeen approved by the USDA as an aid to eliminate Salmonella on rawpoultry carcasses. In the combined operations trisodium phosphate isapplied to the poultry carcasses, and one or more of the microbiocidesof this invention, preferably one or more of the bromine-basedmicrobiocides of this invention, are utilized in sanitizing theequipment, instruments, and/or apparatus associated with the processingof the poultry. Also pursuant to this invention the combined operationscan utilize chlorine dioxide treatments along with use of themicrobiocides of this invention. Smith, Meat Processing, 1996, 35(10),47 indicates that chlorine dioxide had been approved by the US FDA foruse in poultry processing water, and in the practice of this inventionone or more microbiocides of this invention, preferably one or more ofthe microbiocides of this invention, viz., (i) at least one DBDAH, or(ii) at least one BCDAH, or (iii) both of (i) and (ii) are utilized insanitation of various items of equipment, instruments, and/or apparatusutilized in the processing of the poultry, and chlorine dioxide is usedto sanitize at least some of the poultry processing water.

Instead of utilizing only (i) at least one DBDAH, or (ii) at least oneBCDAH, or (iii) both of (i) and (ii), in a processing operation pursuantto this invention, mixtures or combinations of at least one of (i),(ii), or (iii) with at least one other microbiocidal agent such as, forexample, trisodium phosphate, sodium hypochlorite, chlorine dioxide,trichloroisocyanurate, or other suitable microbiocides may be utilized.In such mixtures any proportions can be used, but preferably the amountof at least one of (i), (ii), or (iii) in the mixture will be at leastabout 50 wt %.

The adjective “aqueous” means that the solution or medium or whateverother noun the adjective modifies, can be water whether highly purifiedor of ordinary purity such as emanates from the faucet. Since we aredealing with processing of food, it stands to reason that one should notuse unfit, contaminated or poisonous water. Besides naturally-occurringtrace impurities that may be present in, say, potable water in general,such as ordinary well water or municipal water, the adjective “aqueous”also permits the presence in the water of trace amounts of dissolvedsalts such as fluoride often added to municipal water systems. The pointhere is that the term “aqueous” does not restrict the medium or solventto absolutely pure water—the aqueous solution or medium or the like cancontain what would normally be present and/or reasonably be expected tobe present in it under the particular circumstances involved whenemploying water using ordinary common sense.

Compounds referred to by chemical name or formula anywhere in thisdocument, whether referred to in the singular or plural, are identifiedas they exist prior to coming into contact with another substancereferred to by chemical name or chemical type (e.g., another component,a solvent, or etc.). It matters not what chemical changes, if any, takeplace in the resulting mixture or solution, as such changes are thenatural result of bringing the specified substances together under theconditions called for pursuant to this disclosure. As an example, thephase “solution of at least one 1,3-dihalo-5,5-dialkylhydantoin” andphrases of similar import signify that just before being brought intocontact with an aqueous medium such as water, the at least one1,3-dihalo-5,5-dialkylhydantoin referred to was the specified1,3-dihalo-5,5-dialkylhydantoin. The phrase thus is a simple, clear wayof referring to the solution, and it is not intended to suggest or implythat the chemical exists unchanged in the water. The transformationsthat take place are the natural result of bringing these substancestogether, and thus need no further elaboration.

Also, even though the claims may refer to substances in the presenttense (e.g., “comprises”, “is”, etc.), the reference is to the substanceas it exists at the time just before it is first contacted, blended ormixed with one or more other substances in accordance with the presentdisclosure.

Except as may be expressly otherwise indicated, the article “a” or “an”if and as used herein is not intended to limit, and should not beconstrued as limiting, the description or a claim to a single element towhich the article refers. Rather, the article “a” or “an” if and as usedherein is intended to cover one or more such elements, unless the textexpressly indicates otherwise.

This invention is susceptible to considerable variation within thespirit and scope of the appended claims.

What is claimed is:
 1. An apparatus for processing poultry for food in aplurality of processing operations, wherein the apparatus comprises atleast: (a) a scalding vessel or station in which feathered poultrycarcasses are contacted with a hot aqueous medium; (b) picker apparatusor de-feathering station in which feathers are removed from thefeathered poultry carcasses; (c) eviscerating apparatus or aneviscerating station in which de-feathered carcasses are eviscerated;(d) inside-outside bird washing apparatus or station wherein the insidesand the outsides of eviscerated poultry carcasses are cleansed with oneor more streams of an aqueous medium (e) a continuous online processingoperation or station wherein both the inside and the outside of thepoultry carcasses are sprayed, or an offline reprocessing operationwherein both the inside and the outside of the poultry carcasses aresprayed; and (f) at least one chill tank or vessel in which poultrycarcasses are immersed in cold aqueous medium; wherein: (A) at least oneaqueous liquid medium input apparatus or device adapted to provide to atleast one apparatus or station downstream from the scalding vessel orstation, an aqueous medium containing an effective microbial inhibitingamount of active bromine resulting from the addition to the medium of amicrobiocide comprising (i) at least one 1,3-dihalo-5,5-dialkylhydantoinin which both of the halo atoms are bromine atoms and one of the alkylgroups is a methyl group and the other is a C₁₋₄ alkyl group or (ii) atleast one 1,3-dihalo-5,5-dialkylhydantoin in which one of the halo atomsis a bromine atom and the other is a chlorine atom, and both alkylgroups are, independently, C₁₋₄ alkyl groups, or (iii) both of (i) and(ii); (B) at least one aqueous liquid medium-carrying system orapparatus adapted to carry and transmit to the scalding vessel orstation, aqueous liquid medium effluent from at least one apparatus orstation in which the effluent contains bromine residue remaining frominput from the liquid medium input apparatus or device of (A), the atleast one apparatus or station being downstream from the scalding vesselor station; and (C) at least one aqueous liquid medium-carrying systemor apparatus adapted to carry and transmit effluent from the scaldingvessel or station to a waste water treatment or purification facilityadapted to utilize microbial action to reduce the biochemical oxygendemand of waste water resulting from the processing of the poultry forfood.
 2. The apparatus of claim 1 wherein the at least one aqueousliquid medium carrying system or apparatus in (B) is disposed orconnected so as to be adapted to carry and transmit to the scaldingvessel or station, aqueous liquid medium effluent from at least oneapparatus or station to which (i), (ii), or (iii) is adapted to beprovided in (A).
 3. The apparatus of claim 1 wherein the apparatusfurther comprises at least one pre-chill spray cabinet or stationwherein poultry carcasses are sprayed with cold aqueous medium to reducethe temperature of the carcasses being sprayed.
 4. The apparatus ofclaim 3 wherein the apparatus further comprises a post-chill dip orspray apparatus or station in which poultry carcasses from the chilltank are rinsed with cold aqueous medium.
 5. The apparatus of claim 4,wherein the at least one aqueous liquid medium carrying system orapparatus in (B) is disposed or connected so as to be adapted to carryand transmit to the scalding vessel or station, aqueous liquid mediumeffluent from at least one apparatus or station to which (i), (ii), or(iii) is adapted to be provided in (A).
 6. The apparatus of claim 3,wherein the at least one aqueous liquid medium carrying system orapparatus in (B) is disposed or connected so as to be adapted to carryand transmit to the scalding vessel or station, aqueous liquid mediumeffluent from at least one apparatus or station to which (i), (ii), or(iii) is adapted to be provided in (A).
 7. The apparatus of claim 1wherein the apparatus further comprises a post-chill dip or sprayapparatus or station in which poultry carcasses from the chill tank arerinsed with cold aqueous medium.
 8. The apparatus of claim 7, whereinthe at least one aqueous liquid medium carrying system or apparatus in(B) is disposed or connected so as to be adapted to carry and transmitto the scalding vessel or station, aqueous liquid medium effluent fromat least one apparatus or station to which (i), (ii), or (iii) isadapted to be provided in (A).